Annual Report 2019

Case studies

Strategy delivery case study – Chemicals

Lubrizol Zeue Project - La Prote, Texas

Worley was engaged by Lubrizol to undertake the engineering, procurement and construction of a proprietary chemicals plant in La Porte Texas. The Zeus Project was complete in 2019 with over 90% of the detailed design having been completed by the Global Integrated Delivery (GID) team in India. Full integration of construction management tools created measurable efficiencies in advanced work packaging (AWP) processes. Our Indian procurement personnel co-located in Chinese supplier shops, interfacing between engineering and fabricators. This resulted in expedited work processes, real time decision making and appropriate prioritisation of tasks.

Strategy delivery case study – MMM

Khouribga, Morocco – Beni Amir phosphate wash plant

JESA, our 50/50 joint venture with OCP Group, is a powerful combination, enabling us to successfully deliver projects in Morocco and internationally. This is key to our North Africa and global phosphates strategy.

The Beni Amir Phosphate Wash Plant is an example of an industry leading project where JESA had the Project Management Consulting (PMC) role. The project was unique in the world for a phosphates project, and included a 190 km long pipeline, the longest of its kind in the world. The project was recognized in 2016 as a sustainable development project under 22nd Conference of the Parties (COP 22), based on its water savings, greenhouse gas emissions, as well as transportation costs and capacity.

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Strategy delivery case study – MMM

Oyu Tolgoi Underground Copper Mine – Mongolia

Worley delivered EPCM services for the expanded underground development and copper processing facility. Our delivery team included personnel from Australia, Chile, South Africa and Mongolia with deep expertize and domain knowledge in mining including underground and surface material handling, shaft sinking, mineral processing and infrastructure.

Our Innovative engineering approach resulted in decreased capital expenditure, improved safety outcomes and ongoing operational benefits resulting in cost savings, including improvement to foundations, heating and conveyors.

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Strategy delivery case study – MMM

CHEMETICS

Chemetics became part of the Worley Group post the ECR acquisition and delivers technology and solutions for sulphuric acid and other specialty chemical facilities globally, from greenfield projects to maintenance and turnarounds. This is achieved through Chemetics’ research and development lab and custom-built fabrication facility in Canada, global transportation and logistics management capabilities, specialized project teams and worldwide network of trusted suppliers.

Over the past 50 years, Chemetics’ full life cycle solutions and equipment have enabled more than 800 sulfuric acid plants achieve higher capacities and availability, lower operating costs, decreased emissions and exceptional safety performance.

As the original developer and owner of processes for chlorine dioxide and sodium chlorate production, Chemetics continues to support the pulp industry through our bleaching chemical technologies.

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Strategy Delivery case study – Power and New Energy

Intermittent Dynamic Electrowinning of Electrolytic Manganese Metal – Western Australia

Element 25 (E25) owns and operates the Butcherbird High Purity Manganese Project, developing Australia’s largest-known onshore manganese resource located in Western Australia. The main products to be produced include high-purity Manganese Sulphate (MnSO4) which can be used as an NMC (Nickel-Manganese-Cobalt) cathode in Lithium Ion (Li-Ion) batteries, and Electrolytic Manganese Metal (EMM) for stainless steel and other speciality steel markets.

Producing EMM requires an energy-intensive process called electrowinning, which recovers metal, like manganese, from a solution by passing a current through it. The process traditionally relies on stable current, with energy sourced from cheap baseload options such as coal or hydro. Based on E25’s scoping study, using gas as a potential power source, projected power costs would

contribute approximately 40% of total project costs, with 90% being used solely for EMM production. Due to the remote location and lack of access to cheap energy sources, E25 engaged Advisian to provide lower-cost power options to improve the economics of the Butcherbird High Purity Manganese Project.

Advisian identified a solution to reduce power costs through the use of renewable energy. E25, along with Advisian, are currently investigating the use of Intermittent Dynamic Electrowinning (IDE) generated through wind and solar, and what impact that will have on the electrowinning process. If viable this will allow E25 to access a clean and cheap energy source, that will also improve the cost competitiveness of the EMM produced.

Strategy delivery case study – Onshore

Khazzan Gas Project – Oman

Selected as BP’s EPCM partner for the long-term complex USD16 billion program, providing key leadership and technical specialist services for the gathering, well sites, export systems and supporting infrastructure. The project was led from Oman and was supported by the UK and our high value engineering center in India. Phase 1 was delivered ahead of schedule and under budget resulting in beneficial production being achieved two months ahead of schedule, and with over 33 million hours incident free. The project was awarded the 2019 MEED best project in the Middle East award.

Strategy delivery case study – Digital

CAROL

Advisian Digital has commercialized an internally developed technology and taken to market the first commercial robot for catalyst and adsorbent unloading from LNG, gas plant and refinery vessels. In response to increasingly stringent requirements to reduce human risk in inert confined space entry and turnaround operations, the CAROL (Catalyst Removal Amphirol) robot is an innovative solution to a legacy problem.

To date, successful in plant trials have been conducted at Chevron (Australia), Southern Company (USA) and Imperial Oil (Canada). These trials have demonstrated that CAROL removes the need to have a human inside a compromised and confined space (vessel) during catalyst vacuuming operations. As a result, human safety can be improved by a factor of 10 and the turnaround duration has proven to be reduced by at least 20%.

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Strategy delivery case study – Digital

Keystone XL Data Visualization and Advanced Analytics

Advisian Digital built a data foundation for the Keystone XL construction project that provided access to data from many different project delivery systems provided by Worley, TC Energy and other 3rd parties. The Assure platform was used to provide a data hub. Through Assure, the project is utilizing the visualization environment for advanced/predictive analytics to provide insights to the project leadership in near real time so that timely and well informed decisions can be made.

This type of environment, built at this scale, is new to the large bore pipeline project industry and TC Energy is already seeing the benefits, even before full scale construction has started.

In TC Energy, Advisian Digital has found a willing partner to push this technology forward in a sustainable way that is wholly focussed on delivering for this progressive customer.

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Gulf of Mexico

We are currently implementing solutions on an active construction site on the Gulf Coast of the United States. This project has savings targets for each solution below and is expecting an estimated 150% return on the investment cost of this deploying this technology solution.

  • Workflow Digitization: Traditional pen-and-paper systems were replaced with real time connected tablets/electronic forms and streamlined work processes;
  • Time and Cost Management: The integration of separate tools and systems to automate the flow of information in and out of our solutions. Additionally, productivity is available near real time as timesheets and quantity tracking forms are completed and submitted;
  • Personnel Location: Individual tracking devices connected through a Wi-Fi mesh of wireless access points and integrated into an analytics dashboard allowed real time monitoring of hundreds of craft laborers for safety and productivity improvements;
  • Material Location: RFID-based material tracking system using mobile and vehicle mounted readers improved site material management and craft productivity; and
  • Equipment Location and Utilization: Individual tracking devices installed on construction equipment enable the site to monitor location and usage of rental equipment. When use of equipment is not maximized, the construction managers are able to make informed decisions and reduce cost.
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Strategy delivery case study – Onshore

MEGlobal - US Gulf Coast – BOOKRAMEG project

Design and construction of a world scale MEG facility. Project mechanical completion within schedule incentive bandwidth established by customer. Project issued 90% of equipment purchase orders in a three-month time period which met target expectation established at project start. Identified USD33.5 million in savings during FEED phase.

Strategy Delivery case study – Power and New Energy

Lake Turkana Wind Power Project - Kenya

Worley completed the Lake Turkana Wind Power Project in Kenya. Installing 365 turbines in 362 days in one of the most remote places on the planet with full support and engagement of the local community.

It will now deliver 310MW of power for a million Kenyan households which truly fulfils our purpose of helping our customers meet the world’s changing resources and energy needs.